Steel sidelight frame

ABSTRACT

A knockdown entrance door unit, especially for residential installation, wherein sidelight panels are arranged at one or both sides of the door. The entrance unit includes a low profile sill that spans the entire space between the side jambs. The unit is made as a knockdown structure to reduce shipping expense and possibility of damage during transit to the job site.

o United States Patent 1191 111 3,811,238 Brinker ,May 21, 1974 STEEL SIDELIGHT FRAME 3,568,383 3/1971 .Iudkins ct ul 52/210 1 6 419 B' k 1m 51232 1.9;; [73] Assignee: American Standard Inc., New York, FOREIGN PATENTS OR APPLICATIONS 1,190,236 4/1970 Great Britain 49/504 [22] Filed; July 11, 1972 621,409 6/l96l Italy 52/206 [211 App! 270788 Primary Examiner-Henry C Sutherland Assistant Examiner-Leslie A. Braun [52] US. Cl. 52/204, 52/241 Attorney, Agent, or Firm-Jefferson Ehrlich; Robert [51] Int. Cl E06b 1/22' G. Crooks [58] Field of Search 52/476, 475, 241; 49/504 1 [57 ABSTRACT [56] References C'ted A knockdown entrance door unit, especially for resi- UNITED STATES PATENTS dential installation, wherein sidelight panels are ar- 1,994,203 3/1935 Waldman.....' 52/205 x rang d at on r both sides of the doonThe entrance 3.593.473 7/1971 Kin 52/204 unit includes a low profile sill that spans the entire. 3,429,076 2/1969 Fortsch et al.. 49/504 space between the side jambs. The unit is made as a g g g knockdown structure to reduce shipping expensean'd v C 8C 3.122.223 2/1964 Chell et al. 52 475 'posslblhty of damage durmg trans" to the Job Site 3,340,655 9/1967 Darrah 4... 52/242 X 7 Claims, 10 Drawing Figures PATENTEBmznm I 3 811'238- SHEET 3 0F 3 v v 1 STEEL SIDELIGIFIT FRAME THE DRAWINGS FIG. 1, 2 and 3 are exterior elevational views of various entrance door units embodying the invention.

FIGS. 4, and 6 are enlarged fragmentary sectional views taken on lines 4-4, 5-5, and 66 in FIGS. 1 and 3.

FIG. 7 is a perspective view illustrating a headermullion joint employed in the units of FIGS. 1, 2 and 3.

FIG. 8 is a perspective view ofa sill-mullion joint and a sill-jamb joint employed in the units of FIGS. 1, 2 and 3.

FIG. 9 is a fragmentary perspective view ofa headerjamb joint employed in the units of FIGS. 1, 2 and 3.

FIG. 10' is an enlarged fragmentary sectional view taken on line 99 in FIG. 3.

THE PRIOR ART US. Pat. Nos. 3,205,630 and 3,593,473 are believed to be representative of the prior art.

I THE DRAWINGS ILLUSTRATING THE INVENTION FIG. 1 illustrates an entrance door unit I0 of this invention, comprising a full width header 12, a full width sill 14, two adult height side jambs l6 and 18, and a mullion 20. The space between mullion and jamb 16 is occupied by a movable door 22 hinged to jamb 16 while the space between mullion 20 and side jamb 18 is occupied by a fixed panel 24.

FIG. 2 illustrates an entrance door unit that is similar to the unit of FIG. 1, except that the FIG. 2 unit includes two mullions 20 and 20a, and two fixed panels 24 and 24a. Sill l4 spans the entire width of the unit.

FIG. 3 illustrates an entrance door unit that is generally similar to the FIG. 1 and FIG. 2 units. However, in

the FIG. 3 unit the header and .sill are elongated to accommodate double doors 22 and 22a. Additionally each of the fixed panels in the FIG. 3 unit includes a metallic kick plate 26 adjacent the sill and a glass pane 28 above the kick plate. In the FIG. I and FIG. 2 units the side panels 24 and 24a would generally be wood panels or perhaps foam core plastic panels; hence such units would not require the kick plate that is necessary The various headers. jambs. and mullions are of conventional cross section; As shown in FIG. 4, the header comprises a channel having a rib 30 which forms a stop surface for the wood panel 24 (and also for the movable door 22). A channel shaped glazing bead 32 is screwed into the header to retain the panel in place. Side jambs l6 and 18 are the same cross section as header 12 so that glazing beads (not shown) can be screwed thereto to provide additional retaining structure for panel 24.

FIG. 6 illustrates the cross section of jamb 16; FIG. 10 partially illustrates the cross section ofjamb 18. As

shown in FIG. 6. the mullion 20 is of generally T cross section to provide stop surfaces for panel 24 and door 22. A glazing bead 32 can be screwed to the mullion to lock the panel thereto.

or desirable when glass panes 'are employed. asin FIG.

FIG. 4 illustrates the joint between the lower edge of panel 24 and sill 14. A plastic cap 34 overlies the upper surface of the sill to retard transmission of heat between indoor space and outdoor space 37; the weight of panel 24 is borne by the cap. A wooden bead 36 may be nailed on the left face of the wooden panel to provide an improved exterior appearance and improved weather-sealing action. Preferably the four-sided skeletal frame (members l0,12,l4,l6,l8 and 20) would be fabricated before installation of panel 24 into the frame. Bead 36 wouldpreferably be nailed onto the panel after the panel was in place in the frame.

As previously noted, the frame is adapted to be used with various types of panels, the criteria being primarily the desired ornamental effect and needfor light transmission, i.e., should the home owner required light for viewing the outdoors or for admitting sunlight into the building interior.

FIGS. 3, 5 and 10 illustrate the frame as used with glass panes 28 and metal kick plates 26. As shown in FIG. 10, the metal kick plate is retained between side frame 18 and mullion 20 by means of two internal rails 38 suitably screwed onto members 18 and 20. Plate 26 is of hollow construction such that it can be installed on rails 38 by a downward sliding movement therealong.

As seen in FIG. 5 kick plate26 comprises two parallel vertical walls 40 and 42 and an interconnecting upper wall 44; preferably these walls are formed from a single metal sheet suitably bent in a press brake operation. The hollow wall structure is reinforced at its lower edge by means of a channel 46 suitably welded to walls 40 and 42. As previously noted, the hollow wall structure is installed in the skeletal frame by a downward manual movement along the fixed rails 38 (FIG.

Kick plate 26 is configuredto include an upstanding stop surface 48 (FIG. 5) that lies in the plane of the stop surfaces formed on header 12, the side jambs, and mullion 20. The various stop surfaces form a peripheral frame surface for accepting the glass pane 28. Suitable place to retain the pane in the .frame. g

The skeletal frame is designed to accommodate either the wooden panel 24 or the composite glass-metal kick plate panel.

As previously indicated the skeletal frame is assembled prior to insertion of the panels. Assembly of the frame involves certain manual operations that are best visualized by reference to FIGS. 7, 8 and 9. FIG. 7 illustrates the connection between header l2 and mullion 20. FIG. 8 illustrates the connection between sill l4 and the mullion, a'ndalso the connection between the sill and one of the side frames 16; the connection between the sill and the other side frame 18 would be similar to the one shown in FIG. 8. FIG. 9 illustrates a connection between jamb I8 and header 12; a similar connection would be employed between jamb 16 and the header.

As seen in FIG. 9,jamb 18 is equipped with weldedon plates 50 that form tabs 52; an additional tab 54 is formed on the rib portion of the jamb. When header 12 is forced downwardly onto jamb 18 the tabs enter into slots 56 preformed in the header. By bending the protruding ends of the tabs it is possible to lock the header and jamb-l8 together. A similar procedure can beused to lock the header to jamb l6.

The lower edge area of each jamb 16 or 18 is cut away, as at 58 (FIG. 8) to permit the side surface ofthe jamb to abut flush against the end edge of sill 14 without interference from rib 30. The jamb and sill are interlocked together by means of tabs 60 formed on rib 30 and slots 62 punched or otherwies formed in sill 14. The jamb is installed on the sill by a downward motion of the jamb.

The jamb is locked to the sill by one or more screws 64 that extend through holes 66 in the jamb into anchorage openings in the sill. These anchorage openings are preferably formed as an incidental part of the sillforming operation. in practice the sill is formed as an aluminum extrusion to the cross section generally pictured in FIGS. 4 and 5. As thereshown, the extrusion includes two small cirular channels 68-and 70 ofa size slightly smaller than the diameter of screws 64 (FIG. 8}. Holes 66 are located to be in alignment with channels 68 and 70 when the tabs60 enter slots 62, whereby screws 64 can be turned into the defined anchorages to lock the jamb to the sill. The operation is somewhat the same as described in U.S. Pat. No. 3,33l,-l6l issued on July l8, i967 to R. O. Ruff(see screw 38).

By connecting jambs 16' and 18 to header [2 and sill 14 his possible to form a hollow rectangular frame. One or more mullions 20 and 20a may be assembled within this frame by first wedging the mullion into place between the header and sill, and then driving screws into suitable anchorages within the mullion. The mullion anchorages, as shown in FIGS. 7 and 8, take the form of four steel angles 72 welded inside the mullion adjacent its upper and lower ends. Suitable openings are preformed in the angles to align with factoryformed holes 74 in the sill and header when the mullion is wedged into the desired position. Screws 76 can be" MANUFACTURlNG FEATURES The interfitting parts of the frame are designed to permit formation of the header, jambs and mullions as rolled steel structures by press brake operations. and formation of the sill as an aluminum extrusion. Such an extrusion can be formed with various intricate reinforcement ribs and tread ridge surfacesin a manner not possible with it rolled steel sill sonstruction.

The rolled steel components can be accurately punched and blanked at their ends to form the necessary'holes. slots and tabs for connection of the frame components. The aluminum extrusion can be sawed and faced square at its ends to have a good flush fit with jambs l6 and 18. Preferably the slots 62 are formed,

after the sill has been formed to its final length so that the slots are sccurately spaced with relation to the end face of the sill and the mating surface of the jamb. With such an arrangement the tabs 60 and slots 62 interlock the sill and jambs together in a firm non-wobble relationship. Screws 64 act primarily toprevent withdrawal of the tabs from the slots.

STORAGE SHlPPlNG FEATURES The frame, when knockdowned, occupies reiatively small space. Accordingly the frame components can be bundled together into a relatively compact bundle for storage and shipment. By suitably wrapping the bundle in a corrugated paper wrapper or the like it is possible to protect the bundle from such transit damage as warping, bending, scuffing, ect. The number of small loose parts in each bundle is relatively small because the frame is designed so that no special connectors are required. The only loose connectors are the screws, which are easily replaced at the job site if they should be lost in shipping or transit.

ASSEMBLlNG THE FRAME The frame is designed so that no special tools are required to assemble the components into a finished frame. The various screw anchorages in sill 14 and mullion 20 are concealed or otherwise located such that the cooperating screws 64 and 76 are invisible when the frame is installed in the wall of a building.

The frame design is somewhat unusual in that it includes a reinforcing mullion, and a sill that spans the entire space between the two jambs 16 and 18. The four-sided frame that is thereby formed is much more rigid than the'usual three-sided framethat is conventional in the art. The additional disposition of the mullion between the header and sill further rigidifies the frame. Accordingly the frame possesses a selfsustaining character that is beneficial in ensuring squareness and rigidity during the installation process. The workman can more easily handle such a rigid fours'idedframe, as contrasted with'theconventional threesided structure'The' structure can be further rigidified by installing panel 24 or kick plate 26 in the frame prior to installation of the frame in the building. The rigidity is preferably such that the installed unit has a true square orientationof the frame components without any affirmative procedures being required of the installing workman.

A feature of the invention is that it provides the transit-storage advantages of knockdown structures, and the easy installation advantages usually only associated with factory-welded structures.

I claim:

l. A knockdown entrance door unit comprising a closed rectangular frame which includes'a full width header, a full width sillhavin g a substantially flat segment and a segment sloped downwardly from the flat segment, adult height side jambs each separately connectable at the job site with end areas of the header and sill, and at least one T-shaped mullion separately connectable at the job site with intermediate areas of the header and sill to reinforce the connection between theheader and the sill. at least one door movably positionable in one of the spaces circumscribed by the frame between said mullion and one of the side jambs of the frame, and at least vone panel fixedly positionable in the remaining space circumscribed by the frame, the connections between the header, jambs, sill and mullion being such that the frame can be assembled into a rigid self-sustaining unit prior to its installation in the wall of a building,'said connections including two L-shaped anchorages for receiving the opposite ends of said mullion, said anchorages being respectively mounted on said header and on said sill for holding said mullion therebetween, said mullion being fixedly connected to the header and sill by means of screws insertable through the sill and header into the respective anchorages concealed within the mullion, said side jambs being connected to the sill be means of tabs depending from the jambs into slots in the upper face of the sill.

2. The unit of claim 1 wherein the tabs are prevented from pulling out of the slots by means of screws extending horizontally through the jambs into anchorages within the sill.

the kick plate,

3. A knockdown entrance door unit comprising a closed rectangular frame which includes a full width header, a full width sill having a substantially flat segment and a segment sloped downwardly from the flat segment, adult height side jambs each separately connectable at the job site with end areas of the header and sill. and at least one T-shaped mullion separately connectable at the job site with intermediate areas of the header and sill to reinforce the connection between the header and the sill, at least one door movably positionable in one of the spaces circumscribed by the frame between said mullion and one of the side jambs of the frame, and at least one panel fixedly positionable in the remaining space circumscribed by the frame, the connections between the header, jambs, sill and mullion being such that the frame can be assembled into a rigid selfsustaining unit prior to its installation in the wall of a building, said connections including two L-shpaed anchorages for receiving the opposite ends of said mul lion, said anchorages being respectively mounted on said header and on said sill for holding said mullion therebetween, and the header, sill and mullion being connected together through the anchorages by means of fasteners that are insert able or otherwise assessible from zones around the outer edges of the frame, whereby said fasteners are concealed when the frame 5. A knockdown building entrance doo'runit comprising a rectangular frame which includes a full width header, a full width sill having a substantially flat segment and a segment sloped downwardly from the flat segment, adult height side jambs each separately connected with end areas of the headerand sill, and at least one T-shaped mullion separately connected with and spanning intermediate areas of the header and sill, the

connections between the jambs, header and sill being tab-slot connections, two L-shaped anchorages corresponding to the mullion to receive and hold the respective opposite ends of the mullion, themullion being mounted in said anchorages so that the connections between the mullion, header and sill will be completed by screw connections.

6. The unit of claim 5 wherein the mullion is adapted to have its end surfaces abutted against the lower surface of the header and the upper surface of the sill; said sill and header having connector screws adapted to e'xtend therethrough into anchorages concealed within the mullion.

7. The unit of claim 5 wherein the sill is an extruded metal component having flat end faces abutted against side faces of the jam-bs; said'jambs having inwardly facing ribs that are cut away at theirlowenends to accomodate the sill; said ribs having downwardly extending tabs adapted to project into slots in the upper face of the sill; 

1. A knockdown entrance door unit comprising a closed rectangular frame which includes a full width header, a full width sill having a substantially flat segment and a segment sloped downwardly from the flat segment, adult height side jambs each separately connectable at the job site with end areas of the header and sill, and at least one T-shaped mullion separately connectable at the job site with intermediate areas of the header and sill to reinforce the connection between the header and the sill, at least one door movably positionable in one of the spaces circumscribed by the frame between said mullion and one of the side jambs of the frame, and at least one panel fixedly positionable in the remaining space circumscribed by the frame, the connections between the header, jambs, sill and mullion being such that the frame can be assembled into a rigid self-sustaining unit prior to its installation in the wall of a building, said connections including two L-shaped anchorages for receiving the opposite ends of said mullion, said anchorages being respectively mounted on said header and on said sill for holding said mullion therebetween, said mullion being fixedly connected to the header and sill by means of screws insertable through the sill and header into the respective anchorages concealed within the mullion, said side jambs being connected to the sill be means of tabs depending from the jambs into slots in the upper face of the sill.
 2. The unit of claim 1 wherein the tabs are prevented from pulling out of the slots by means of screws extending horizontally through the jambs into anchorages within the sill.
 3. A knockdown entrance door unit comprising a closed rectangular frame which includes a full width header, a full width sill having a substantially flat segment and a segment sloped downwardly from the flat segment, adult height side jambs each separately connectable at the job site with end areas of the header and sill, and at least one T-shaped mullion separately connectable at the job site with intermediate areas of the header and sill to reinforce the connection between the header and the sill, at least one door movably positionable in one of the spaces circumscribed by the frame between said mullion and one of the side jambs of the frame, and at least one panel fixedly positionable in the remaining space circumscribed by the frame, the connections between the header, jambs, sill and mullion being such that the frame can be assembled into a rigid selfsustaining unit prior to its installation in the wall of a building, said connections including two L-shpaed anchorages for receiving the opposite ends of said mullion, said anchorages being respectively mounted on said header and on said sill for holding said mullion therebetween, and the header, sill and mullion being connected together through the ancHorages by means of fasteners that are insertable or otherwise assessible from zones around the outer edges of the frame, whereby said fasteners are concealed when the frame is installed in a building wall, the sill-jamb connections including interlocking tab-slot structures arranged to resist loads normal to the plane of the frame unit.
 4. The entrance door unit of claim 3 wherein one of the panels includes a kick plate installable between a mullion and side jamb in the space immediately above the sill, and a glass pane installable in the space above the kick plate.
 5. A knockdown building entrance door unit comprising a rectangular frame which includes a full width header, a full width sill having a substantially flat segment and a segment sloped downwardly from the flat segment, adult height side jambs each separately connected with end areas of the header and sill, and at least one T-shaped mullion separately connected with and spanning intermediate areas of the header and sill, the connections between the jambs, header and sill being tab-slot connections, two L-shaped anchorages corresponding to the mullion to receive and hold the respective opposite ends of the mullion, the mullion being mounted in said anchorages so that the connections between the mullion, header and sill will be completed by screw connections.
 6. The unit of claim 5 wherein the mullion is adapted to have its end surfaces abutted against the lower surface of the header and the upper surface of the sill; said sill and header having connector screws adapted to extend therethrough into anchorages concealed within the mullion.
 7. The unit of claim 5 wherein the sill is an extruded metal component having flat end faces abutted against side faces of the jambs; said jambs having inwardly facing ribs that are cut away at their lower ends to accomodate the sill; said ribs having downwardly extending tabs adapted to project into slots in the upper face of the sill. 